Cylinder Head, Removing And Installing: Removing

WARNING: This page is about a different car, the 2014 Volkswagen Touareg, 2013 Volkswagen Touareg, 2012 Volkswagen Touareg, and 2011 Volkswagen Touareg. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION:

Note The Following whenever working inside the engine compartment due to limited space:

Route all lines and cables in their original locations.
Ensure sufficient clearance to all moving or hot components.

NOTE:

All cable ties which are opened or cut open when removing, must be replaced in the same position when installing.

When the engine is installed in the engine compartment some components cannot be removed or can only be removed with great difficulty. Therefore determine which components are faulty before removing so that they can replaced while they are removed.

To prevent damage to removed components, use the :VAG1698 for storage.

-- Remove the intake manifold upper section. Refer to INTAKE MANIFOLD UPPER SECTION, REMOVING AND INSTALLING .

-- Remove the high pressure pump. Refer to HIGH PRESSURE PUMP, REMOVING AND INSTALLING .

-- Pull out pump plunger -item ) OVERVIEW - VALVE TRAIN - PUMP PLUNGER.

-- Unscrew the heat shield and the intake manifold support from the cylinder head.

-- Disconnect the following connectors.

Fig 1: Camshaft Adjustment Valve & Camshaft Position (CMP) Sensor

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Camshaft Position Sensor -G40-
Camshaft Adjustment Valve 1 -N205-
Camshaft Position Sensor 2 -G163-
Exhaust Camshaft Adjustment Valve 1 -N318-

-- Pull off/disconnect all remaining electrical wires required from cylinder head and set aside.

-- Remove the bracket from the camshaft timing chain cover.

-- Remove the three bolts -1 through 3- at the coolant connection.

Fig 2: Identifying Three Mounting Bolts On Coolant Connection

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-- Remove the cylinder head cover.

-- Turn the crankshaft using the :T10172 in the direction of engine rotation to the Top Dead Center (TDC) marking -arrow-.

Fig 3: Identifying Cylinder 1 At Top Dead Center (TDC) Mark

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Cams -A- of cylinder 1 must face each other.

Fig 4: Camshaft Lobes For Cylinder Facing Each Other

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-- Remove the vacuum pump. Refer to MECHANICAL VACUUM PUMP, REMOVING AND INSTALLING .

-- Unscrew both retaining bolts -1- from the sealing flange and then unscrew all retaining bolts -arrows- from the cover.

Fig 5: Identifying Sealing Flange And Cover Bolts

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-- Remove chain tensioner for camshaft timing chain -arrow-.

Fig 6: Chain Tensioner Bolt Camshaft Roller Chain

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NOTE:

Counterhold the camshaft with a 27 mm open end spanner insert -arrow-. The :T10068A must not be inserted when tightening or loosening camshaft adjuster.

Fig 7: Counter-Holding At Camshaft Using Wrench

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-- Remove mounting bolts -1 and 2- and then remove bolts of glide track -3-.

Fig 8: Camshaft Adjuster Mounting Bolts And Bolts Of Glide Track

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NOTE:

The camshaft timing chain is held by the lower timing chain cover on the oil pump chain sprocket. The timing chain cannot skip.

-- Remove the camshaft adjuster from the camshafts.

-- Remove the camshaft timing chain from the high pressure pump chain sprocket.

-- Remove the four bolts -arrows- from the control housing and then pull the control housing downward from the camshaft.

Fig 9: Identifying Control Housing And Bolts

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-- Cover camshafts -arrows- with clean paper strips and wrap ends with adhesive tape.

Fig 10: Covering Camshafts With Clean Paper Strips And Wraping Ends With Adhesive Tape

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-- Loosen and unscrew cylinder head bolts in specified sequence starting from outside working toward inside.

Fig 11: Cylinder Head Bolt Removal Sequence

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-- Engage the : 3033 as shown and raise the cylinder head carefully using the :VAS6100 or :VAG1202A :

Fig 12: Hooking Engine Sling 3033 Onto Engine And Onto Workshop Crane VAS 6100

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Vibration damper side: position 3

Flywheel side: Position 11

NOTE:

The :3033 items marked 1 through 12 face toward the flywheel side.

Threaded spindles are set in length according to necessity.

-- Carefully lift cylinder head off.

-- Stuff clean cloths into cylinder so that no dirt or abrasive powder can get between cylinder wall and piston.

-- Do not allow dirt or abrasive powder to get into coolant either.

-- Carefully clean sealing surfaces on the cylinder head and cylinder block. Avoid introducing scratches or scoring (do not use sandpaper with grit below "100").

-- Clean all threaded bores for cylinder head bolts.

-- Checking cylinder head for distortion. Refer to Figure.